Systems and methods for processing comestibles

ABSTRACT

In some implementations, a banded discharge removes or rejects comestibles from a production line when the comestibles have a diameter less than a minimum value. The banded discharge may include two or more support members and each pair of adjacent support members may be spaced apart a distance W. When a comestible with a diameter about the same as or less than the distance W moves onto the banded discharge, the banded discharge may remove the comestible from the production line. For example, the comestible may fall between two adjacent support members.

BACKGROUND

Flatbread is made from flour, water, and salt and formed into flatteneddough before baking. Some flatbreads include additional ingredients suchas curry powder, black pepper, olive oil, or sesame oil. The thicknessof the flattened dough can range from one thirty-second of an inch toover an inch thick.

Flatbreads are made by hand or with automated equipment. For example, afactory or a production line can be used to produce one or more types offlatbread to reduce the cost of making the bread. One automated methodof forming flatbread includes pressing flatbread dough.

Factories can include different types of tools for the different stagesin the production process, such as a mixer, an oven, and a cooler. Someproduction lines have a tool to form flatbread dough into a ball andanother tool to flatten the dough before baking. The flattened dough hasa circular shape and a specific thickness so the flatbread will have adesired thickness after baking.

For example, a pressing apparatus presses a ball of dough until thepressed dough ball has a certain diameter. After the pressure isreleased from the pressed dough ball, the diameter of the pressed doughball sometimes decreases due to elasticity of the dough. Changes todifferent process parameters, such as a heating temperature duringpressing and the ingredients in the dough, sometimes have an effect onthe diameter of the dough after pressing is completed. For example, ahigher pressing temperature can help a pressed dough ball retain itsshape.

SUMMARY

In some implementations, a banded discharge removes or rejectscomestibles from a production line when the comestibles have a diameterless than a minimum value. The banded discharge may include two or moresupport members and each pair of adjacent support members may be spacedapart a distance W. When a comestible with a diameter about the same asor less than the distance W moves onto the banded discharge, the bandeddischarge may remove the comestible from the production line. Forexample, the comestible may fall between two adjacent support members.

In a preferred embodiment, the banded discharge rejects comestibles witha thickness greater than a predetermined thickness to prevent a jam inthe production line. For example, the diameter and thickness of acomestible are inversely proportional. When the comestible has adiameter less than the distance W, the comestible may have a thicknessgreater than a predetermined thickness and may clog the production line.

In various implementations, the banded discharge includes two rollersthat support and translate the support members. A distance between thetwo rollers is optionally less than a desired comestible diameter. Forexample, the distance between the two rollers may be about 2 inches lessthan the desired comestible diameter.

In various implementations, each of the support members may have adiamond cross section. In other implementations, each of the supportmembers may have an inverted “V” cross section. Each of the supportmembers may be manufactured from polyurethane. In certainimplementations, each of the support members may be made form anelastomer. The hardness of each of the support members may be betweenabout 50 to about 100 Durometer.

A desired diameter of the comestible may be specified by a productionline process recipe. For example, the recipe may include a range for thedesired diameter of comestibles pressed in the production line. Thesupport members in the banded discharge may be positioned based on aselected recipe or input recipe parameters. The distance between therollers that support the support members and the lengths of the supportmembers may be determined based on the production line recipe.

In some implementations, the banded discharge can be positioned betweentwo additional conveyors. In other implementations, the banded dischargecan be located between a conveyor and an apparatus (e.g., a pressingapparatus).

The details of one or more implementations are set forth in theaccompanying drawing and description below. Other features, objects, andadvantages will be apparent from the description and drawings, and fromthe claims.

DESCRIPTION OF DRAWINGS

FIGS. 1A-D illustrate an example of part of a production line.

FIGS. 2A-E illustrate an example of a transfer system.

FIG. 3 illustrates an example of a system for selecting a productionline process recipe.

FIG. 4 is a block diagram of a computing system optionally used inconnection with computer-implemented methods described in this document.

Like reference symbols in various drawing indicate like elements.

DETAILED DESCRIPTION OF ILLUSTRATIVE IMPLEMENTATIONS

A comestible or flatbread production line includes a dough pressingstation that flattens a ball of dough to a desired diameter beforecooking. Sometimes, the dough pressing station does not press every ballof dough that moves through the production line. For example, if a ballof dough is misaligned with the production line (e.g., with the pressingstation), malformed, or missing, one or more balls of dough may not becorrectly formed (e.g., sufficiently pressed, or have a correct shape)at the pressing station.

The flatbread production line includes a banded discharge that removesor rejects balls of dough that have a diameter equal to or less than apredetermined value from the production line to prevent the balls ofdough from causing a jam or otherwise stopping the production line. Forexample, the banded discharge removes incorrectly formed balls of doughthat have a diameter less than the predetermined value from theproduction line.

The banded discharge includes two or more transfer support members thatsupport formed dough balls with a diameter greater than a predeterminedvalue while allowing incorrectly formed balls of dough with a diameterequal to or less than the predetermined value to fall between adjacenttransfer belts. The incorrectly formed balls of dough are transferredaway from the banded discharge after falling through the aperturebetween adjacent transfer belts.

The location of the banded discharge is determined based on the specificequipment used in the production line. For example, if the productionline includes an oven with multiple conveyors that transfer a presseddough ball between the multiple conveyors, a banded discharge is placedbefore the oven. Alternatively, if the oven includes only a singleconveyor and a cooler includes multiple conveyors, a banded discharge isplaced before the cooler and after the oven.

In some implementations, a banded discharge reduces the down time of theproduction line. For example, the banded discharge eliminates or reducesthe number of jams created by incorrectly formed balls of dough and theneed to clear the jams. Incorrectly formed balls of dough can includeballs of dough that are not pressed at a pressing station, balls ofdough that do not complete a pressing process, or any other shape orsize of dough ball where a horizontal axis of the dough ball is lessthan a predetermined recipe value (e.g., a width W).

FIG. 1A is an example of a dough pressing apparatus 100 a. The doughpressing apparatus 100 a includes a conveyor 102 that receives one ormore balls of dough 104 (e.g., with a width between about 1.5 to about4.0 inches). The balls of dough 104 are placed on the conveyor 102 by aloading station or another conveyor (not shown). The temperature of theconveyor 102 is the same as the ambient environment around the doughpressing apparatus 100 a.

A pattern of dough balls is placed on the conveyor 102 so that each ofthe individual balls of dough aligns with a pressing surface of apressing station 106. For example, three longitudinal columns of theballs of dough 104 are placed on the conveyor 102 to align approximatelywith three longitudinal axes A1-3 of the dough pressing apparatus 100 a.

The conveyor 102 moves the pattern of dough balls into the pressingstation 106, which presses the balls of dough 104 and forms a pluralityof pressed dough balls 108. In some implementations, the pressure usedat the pressing station 106 is adjusted based on the actual diameters ofthe pressed dough balls 108 if a number of the pressed dough balls 108have a diameter that is smaller or larger than the desired diameter. Forexample, if there are nine balls of dough in a press cycle, and six ofthe pressed dough balls 108 have an actual diameter that is smaller thanthe desired diameter, the pressure used by the pressing station can beincreased so that the diameters of the pressed dough balls 108increases.

In certain implementations, some of the balls of dough 104 are notpressed or are not sufficiently pressed in order to prevent the ball ofdough from creating a jam in a production line housing the doughpressing apparatus 100 a. For example, if a loading station places apattern of dough balls on the conveyor 102 that is missing some of thedough balls in the pattern, the pressing station 106 does not press thepattern of dough balls. Alternatively, the pressing station 106 does notcompletely press a pattern of dough balls according to recipespecifications when a dough ball is missing from the pattern of doughballs. In another example, one or more of the balls of dough 104 in thepattern may be malformed or smaller than a recipe size required for theballs of dough 104.

In one example, pressing a pattern of dough balls where one or more ofthe dough balls is missing or incorrectly formed may create anasymmetrical load on the frame of the pressing station 106. In someimplementations, the pressing station 106 does not press or completelypress the pattern of dough balls in order to prevent the asymmetricalload on the frame of the pressing station 106, which may cause extrawear or damage to the pressing station 106 and/or the conveyor 102.

In some implementations, the conveyor 102 moves one or more non-pressedor non-formed dough balls (e.g., the balls of dough 104) past thepressing station 106 before the non-pressed dough balls are pressed atthe pressing station 106. For example, another conveyor (not shown)feeds the balls of dough 104 onto the conveyor 102 and the conveyor 102moves one or more of the balls of dough 104 past the pressing station106. In one example, the conveyor 102 moves one or more latitudinal rowsof the balls of dough 104 past the pressing station 106 while aligningballs of dough with the pressing station 106 (e.g., because of a missingor incorrectly sized ball of dough).

The pressing station 106 optionally includes one or more sensors (e.g.,a photo eye) which detect a missing or incorrectly formed dough ball.When one of the sensors detects a missing or incorrectly formed doughball, a controller can provide a signal to the pressing station 106 sothat the pressing station does not press or completely press the patternof dough balls.

The pressing station 106 includes an upper pressing platen 110 thatapplies pressure downward on the balls of dough 104. The upper pressingplaten 110 includes an upper insulator 112, an upper pressing plate 114,and an upper portion 116. The upper insulator 112 and the upper pressingplate 114 are mounted to the upper portion 116 with non-conductivebolts.

The upper insulator 112 provides thermal insulation so that heat fromthe upper pressing plate 114 does not pass into the upper portion 116 ofthe upper pressing platen 110. The upper insulator 112 is made fromthermalate, such as Thermalate® H330 manufactured by Haysite. The upperinsulator 112 has a maximum service temperature between about 500 toabout 1000° F., preferably between about 500 to about 850° F., morepreferably between about 550 to about 800° F.

The upper insulator 112 has a compressive strength between about 17,000to about 49,000 PSI, preferably between about 26,200 to about 49,000PSI, more preferably between about 26,200 to about 44,000 PSI. In someimplementations, the upper insulator 112 is composed of glastherm, suchas Glastherm® HT or Cogetherm® manufactured by Glastic Corporation.

The upper insulator 112 and the upper pressing plate 114 are square witha length and a width between about 12 to about 72 inches, preferablybetween about 15 to about 60 inches. In certain implementations, theupper insulator 112 has a rectangular shape. In some implementations,the upper insulator 112 and the upper pressing plate are square with awidth and length between about 37 to about 42 inches. The upperinsulator 112 has a thickness between about 0.5 to about 2 inches,preferably between about 0.75 to about 1.75 inches, more preferablyabout 0.75 inches. The size and shape of the upper insulator 112 and/orthe upper pressing plate 114 is determined by the production linehousing the dough pressing apparatus 100 a and the process recipes usedin the production line.

The upper pressing plate 114 includes one or more heating channels (notshown). The heating channels include one or more heating elements thatincrease the temperature of the upper pressing plate 114 duringprocessing. In some implementations, a heating fluid, such as a liquidor a gas, flows through the heating channels in order to heat the upperpressing plate. For example, Argon gas passes through the heatingchannels and heats the upper pressing plate 114 to a temperature betweenabout 150 to about 750° F., preferably between about 250 to about 550°F., more preferably between about 300 to about 400° F. The temperatureof the upper pressing plate 114 is determined based on a process recipeused by the dough pressing apparatus 100 a.

The thickness of the upper pressing plate 114 is selected based on thepressure applied to the balls of dough 104 and the temperature requiredto heat the balls of dough 104 during processing. For example, the upperpressing plate 114 has a thickness between about 1 to about 5 inches,preferably between about 1.5 to about 3 inches. For example, thefinished thickness of the upper pressing plate 114 can be about 2.974inches.

In some implementations, the thickness of the upper pressing plate 114is selected based on the composition of the upper pressing plate 114.For example, when the upper pressing plate 114 is made from graphene,the upper pressing plate 114 is thinner than if the upper pressing plate114 was made from gold.

The upper pressing plate 114 is made from a material with a high thermalconductivity. The upper pressing plate 114 has a thermal conductivitybetween about 5 to about 5500 W/(m*K), preferably between about 15 toabout 2500 W/(m*K), more preferably between about 30 to about 500W/(m*K). The thermal conductivity of the upper pressing plate 114 can beselected based on the process recipes used in the dough pressingapparatus 100 a, the composition of the upper pressing plate 114, and/ora desired efficiency of the upper pressing plate 114.

In some implementations, the composition of the upper pressing plate 114is selected based on the resistance of the material to wear orscratches. For example, stainless steel is used to increase hardness(e.g., durability) and corrosion resistance of the upper pressing plate114. The increased hardness of stainless steel decreases scratches anddents made to the upper pressing plate 114.

In some implementations, the upper pressing plate 114 is manufacturedfrom aluminum or an aluminum alloy in order to have high wearresistance, a light mass, and a reduced heating time (e.g., based on athermal conductivity of about 120 to about 237 W/(m*K)). The upperpressing plate 114 can be made from ceramic material in order towithstand high processing temperatures without deforming (e.g., up toabout 3,000° F.) and have a high wear resistance. Brass can be used forthe upper pressing plate 114 based on the low friction of brassmaterials and good thermal conductivity (e.g., about 109 W/(m*K)).

The upper pressing platen 110 includes a skin 118 that protects thebottom surface of the upper pressing plate 114 from wear caused by heatand/or pressure during processing of the balls of dough 104. The skin118 is attached to the upper pressing platen 110 using vacuum suction.Alternatively, the skin 118 is attached to the upper pressing platen 110using bolts or clamps.

A pressure between about 3 to about 70 PSI is applied to the upperpressing platen 110 to press a bottom surface of the skin 118 againstthe balls of dough 104, preferably between about 5 to about 65 PSI. Insome implementations, a pressure between about 9 to about 50 PSI isapplied to the upper pressing platen 110.

The pressing station 106 uses different pressures based on the desireddiameter of the pressed dough balls 108. For example, a higher pressure(e.g., 48 PSI) is used to create pressed dough balls with a largerdiameter (e.g., 12 inches) and a lower pressure (e.g., 13 PSI) is usedto create pressed dough balls with a smaller diameter (e.g., 5 inches).

The diameter of the pressed dough balls 108 is inversely proportional tothe thickness of the pressed dough balls 108. For example, increasingthe diameter of a specific pressed dough ball decreases the thickness ofthe specific pressed dough ball. In one example, a ball of dough with aspecific volume has a diameter of 10 inches and a thickness of ¼ inches,and a ball of dough with the same volume and an 8 inch diameter has athickness of 25/64 inches.

The pressing station 106 includes a lower pressing platen 120. The lowerpressing platen 120 applies pressure to the balls of dough 104 frombelow during processing. For example, the lower pressing platen 120supports the balls of dough 104 on the conveyor 102 while the upperpressing platen 110 presses down on the top surface of the balls ofdough 104.

The lower pressing platen 120 includes a lower pressing plate, a lowerinsulator, and a lower portion (not shown) similar to the upper pressingplate 114, the upper insulator 112, and the upper portion 116respectively. For example, both the lower pressing plate and the upperpressing plate 114 are manufactured from stainless steel.

In some implementations, the lower pressing plate has a lowertemperature than the upper pressing plate 114 in order to reduce thelikelihood that a ball of dough will stick to the skin 118 after beingpressed. For example, the pressed dough balls 108 are more likely tostick to a cooler surface, so the temperature of the lower pressingplate is less than the temperature of the upper pressing plate 114 andthe skin 118 so that the pressed dough balls 108 will rest on theconveyor 102 after processing instead of sticking to the skin 118 andlifting off the conveyor 102.

For example, the lower pressing plate has a temperature between about150 to about 750° F., preferably between about 250 to about 550° F.,more preferably between about 300 to about 400° F. In one example, whenthe upper pressing plate 114 has a temperature of around 350° F., theskin 118 has a temperature of around 340° F., and the lower pressingplate has a temperature of around 325° F.

The dough pressing apparatus 100 a is configured to process differentrecipes for different types of dough, different sizes of dough, and/ordifferent shapes of dough. For example, different recipes can have adifferent press cycle layout or pattern of dough balls, such as a square2×2 to a square 8×8 layout or a rectangular 5×6 or 4×3 layout. Whendifferent press cycle layouts are used, the dough pressing apparatus 100a includes a number of longitudinal axes based on the number oflongitudinal columns associated with the press cycle layout. Forexample, when using a 5×6 layout with 5 longitudinal columns, the doughpressing apparatus 100 a includes five longitudinal axes A1-3.

After the pressed dough balls 108 are formed at the pressing station106, the conveyor 102 moves the pressed dough balls 108 to a dischargestation 122. In some implementations, the discharge station 122 includesa heater to parbake the pressed dough balls 108. For example, parbakingthe pressed dough balls 108 at the discharge station allow thetemperature of the lower pressing platen 120 to be reduced. In someimplementations, forming the pressed dough balls 108 with a reducedtemperature of the lower pressing platen 120 creates rounder presseddough balls 108.

The pressed dough balls 108 are transferred from the discharge station122 to an oven 100 b, shown in FIG. 1B. For example, a conveyor 124transfers the dough balls to the oven 100 b from the discharge station122.

The oven 100 b includes an oven conveyor (not shown) that transfers thepressed dough balls 108 through the oven 100 b during the cookingprocess. As the pressed dough balls 108 are conveyed through the oven100 b, the pressed dough balls 108 are cooked so that when the presseddough balls 108 exit the oven 100 b, the cooking process is complete.Alternatively, when the pressed dough balls 108 are removed from theoven 100 b by the oven conveyor, the pressed dough balls 108 proceed toanother cooking process.

The oven 100 b includes one or more gas heaters (not shown) to cook thepressed dough balls 108. The gas heaters increase heat control (e.g.,heat uniformity) of the cooking process of the pressed dough balls 108.In certain implementations, when the oven 100 b includes gas heaters,the gas heaters allow the oven 100 b to adjust temperature more quickly.For example, when the production line is initially started the oven 100b heats up to a processing temperature more quickly using gas heaters.Alternatively, the oven 100 b can use electric heaters to cook thepressed dough balls 108.

In various implementations, the oven 100 b is a convection oven. Aconvection oven, for example, provides greater temperature uniformityduring the cooking process. For example, the pressed dough balls 108 arecooked more evenly with an electric convection oven. Alternatively, theoven 100 b is a gas convection oven.

In certain implementations, the oven 100 b uses infrared heat to cookthe pressed dough balls 108. In these implementations, using infraredheat can provide a better distribution of heat in the oven 100 b andcook the pressed dough balls 108 more evenly throughout the dough ball.For example, the oven 100 b can require fewer heating elements whenusing infrared heat. In one example, the middle of a pressed dough ballis cooked approximately the same amount as the edge of the pressed doughball when using infrared heat.

In some implementations, the oven 100 b includes a stack of conveyorswith each adjacent conveyor running in opposite directions across theoven. As each of the pressed dough balls 108 reaches the end of one ofthe conveyors, the pressed dough balls 108 pass through a turnaroundthat flips the pressed dough balls 108 over and places the pressed doughballs 108 on the next conveyor down in the stack of conveyors. Thisallows both sides of the pressed dough balls 108 to be cooked as evenlyas possible in the oven 100 b.

In one example, when the oven 100 b includes a stack of conveyors anduses infrared heat to cook the pressed dough balls, the number ofheating elements needed in the oven 100 b is reduced because theinfrared heat is evenly distributed throughout the oven 100 b. Invarious implementations, using infrared heat reduces the amount of timenecessary to cook the pressed dough balls 108.

In certain implementations, the oven conveyor in the oven 100 b isheated. Heating the oven conveyor, for example, can reduce the amount oftime needed to cook the pressed dough balls 108 because the presseddough balls 108 are cooked on both sides at the same time.

The oven 100 b includes one or more vents 126 a-b that exhaust gasesand/or heat from the oven 100 b and prevent the gases and/or heat fromentering the factory housing the production line. For example, the vents126 a-b draw gases from oven 100 b to prevent the gases from buildingup. The vents 126 a-b bring fresh air into the oven 100 b and/or thefactory housing the production line to prevent a back draft of aircaused by the exhaust of the gases and/or heat from the oven 100 b.Additionally, the vents 126 a-b can remove heat from the oven 100 b asnecessary during the cooking process.

After cooking, the oven conveyor releases the pressed dough balls 108onto a transfer system 100 c, shown in FIG. 1C. The transfer system 100c moves the pressed dough balls 108 from the oven 100 b to a cooler 100d, discussed in more detail below with reference to FIG. 1D.

The transfer system 100 c includes an oven removal conveyor 128. Theoven removal conveyor 128 transfers the pressed dough balls 108 to abanded oven discharge 130, described in more detail below with referenceto FIGS. 2A-E.

The banded oven discharge 130 includes multiple support members thatallow incorrectly formed dough balls to fall between adjacent bands andinto a rejected product cart 132 for removal from the production linewhile the pressed dough balls 108 pass across the banded oven discharge130. Once the rejected product cart 132 is full, the rejected productcart 132 is removed from the production line and another cart is placedbelow the banded oven discharge 130.

Alternatively, a conveyor located beneath the banded oven discharge 130removes incorrectly formed dough balls from the production line area.For example, the conveyor transfers the incorrectly formed dough ballsto another area in the factory housing the production line.

The banded oven discharge 130 transfers the pressed dough balls 108 fromthe oven removal conveyor 128 to a cooling rack input conveyor 134. Thecooling rack input conveyor 134 transfers the pressed dough balls 108into a cooler 100 d, shown in FIG. 1D.

The cooler 100 d includes multiple cooling conveyors (not shown) thattransport the pressed dough balls 108 through the cooler 100 d. As thepressed dough balls 108 move through the cooler 100 d, air moving acrossthe surfaces of the pressed dough balls 108 cools the pressed doughballs 108 to a reduced temperature.

For example, the pressed dough balls 108 have a temperature close to200° F. when entering the cooler 100 d. One or more fans move air fromthe environment outside of the cooler 100 d (e.g., at an ambienttemperature between about 65 to about 80° F., preferably between about70 to about 75° F., more preferably about 72° F.) across the coolingconveyors and the pressed dough balls. As the air passes across thepressed dough balls 108, heat is removed from the pressed dough balls108 and the pressed dough balls 108 are cooled. When the pressed doughballs 108 exit the cooler 100 d, the pressed dough balls 108 are at atemperature close to the ambient temperature of the environment outsideof the cooler 100 d and can be packaged for shipment.

In some implementations, when the cooling conveyors are manufacturedfrom a conductive material, the cooling conveyors reduce the temperatureof the pressed dough balls 108. For example, heat from the pressed doughballs 108 dissipates into the cooling conveyors as the pressed doughballs 108 are transferred through the cooler 100 d. As air from theambient environment blows across the cooling conveyors, some of the heatis removed from the cooling conveyors, reducing the temperature of thecooling conveyors and another cycle of the cooling process begins.

In certain implementations, the cooling conveyors are cooled directly bythe cooler 100 d. For example, the cooler 100 d includes a freezer thatcools the cooling conveyors and provides indirect cooling to the presseddough balls 108. In one example, the cooling conveyors are directlycooled by a refrigerant and the contact between the pressed dough balls108 and the cooling conveyors as the pressed dough balls 108 movethrough the cooler 100 d reduces the temperature of the pressed doughballs 108.

The multiple cooling conveyors in the cooler 100 d are stacked aboveeach other in the vertical direction (e.g., forming a multi-tierconveyor) and each of the conveyors transfers the pressed dough balls108 in a different direction from the other conveyors adjacent to theconveyor.

The cooler 100 d includes at least three conveyors in a multi-tierconveyor stack. In some implementations, the cooler 100 d includesbetween seven and nineteen cooling conveyors. In another implementation,the cooler 100 d includes between nine and twenty-one cooling conveyors,preferably between thirteen and seventeen cooling conveyors.

The number of cooling conveyors included in the cooler 100 d can bedetermined based on the baking temperature of the pressed dough balls108. For example, when the pressed dough balls 108 are baked at a highertemperature, the cooler 100 d includes more cooling conveyors than whenthe pressed dough balls 108 are baked at a lower temperature. The numberof cooling conveyors in the cooler 100 d can be determined based on themaximum or highest allowable temperature of the oven 100 b.

For example, the number and/or length of the cooling conveyorsdetermines the length of time that the pressed dough balls 108 are inthe cooler 100 d and the change in temperature of the pressed doughballs 108. Additionally, the specific cooling methods used to reduce thetemperature of the pressed dough balls 108 affect the number and/orlength of the cooling conveyors.

In some implementations, the alignment of the pressed dough balls 108 asthe pressed dough balls 108 move between adjacent conveyors is used todetermine the number of cooling conveyors in the cooler 100 d. Forexample, systems with more cooling conveyors may sometimes cause apattern of dough balls to become misaligned so that the pattern nolonger includes rows of dough balls that are in a uniform line (e.g.,along a latitudinal axis perpendicular to the longitudinal axes A1-3)compared to a system with fewer cooling conveyors.

In one example, the cooler 100 d includes thirteen cooling conveyors forcooling the pressed dough balls 108 to reduced or ambient temperature. Afirst conveyor in the cooler 100 d transfers the pressed dough balls 108from the left of the cooler 100 d to the right of the cooler 100 d, anda second conveyor directly below the first conveyer transfers thepressed dough balls 108 from the right of the cooler 100 d to the leftof the cooler 100 d.

A turnaround (not shown) connecting the first conveyor and the secondconveyor moves the pressed dough balls 108 between the adjacentconveyors while flipping the pressed dough balls 108 over to increasethe uniformity of cooling of the pressed dough balls 108. The cooler 100d includes a turnaround between each of the adjacent cooling conveyorsto move the pressed dough balls 108 between the adjacent conveyors inthe cooler 100 d.

The banded oven discharge 130 removes the non-pressed dough balls fromthe production line before the non-pressed dough balls can become stuckin a turnaround and cause a jam in the cooler 100 d. In someimplementations, removing non-pressed, incorrectly formed, or smalldough balls from the production line at the banded oven dischargereduces the down time of the production line.

In implementations where the oven 100 b includes multiple conveyors, abanded discharge (e.g., the banded oven discharge 130 and the rejectedproduct cart 132) is located in the production line between the doughpressing apparatus 100 a and the oven 100 b. For example, the presseddough balls 108 are transferred to the banded discharge from theconveyor 124 before entering the oven 100 b. In these implementations,the banded oven discharge 130 is not included in the production lineafter the oven 100 b.

FIGS. 2A-E illustrate an example of a transfer system 200 (e.g., thetransfer system 100 c). The transfer system 200 includes an oven removalconveyor 228, which removes the balls of dough from an oven (e.g., theoven 100 b). A banded oven discharge 230 (e.g., a conveyor) receives theballs of dough from the oven removal conveyor 228 and disposes of one ormore non-pressed or incorrectly formed balls of dough into a rejectedproduct cart 232, shown in FIG. 2A.

For example, a ball of dough that was not flattened at a pressingstation (e.g., the pressing station 106) falls through the banded ovendischarge 230 and into the rejected product cart 232. In anotherexample, a ball of dough that was not sufficiently pressed at thepressing station drops into the rejected product cart 232. In thisexample, the pressing station stopped pressing the ball of dough beforethe diameter of the ball of dough was about the same as a desired recipediameter (e.g., based on a current recipe for the production line).Because the diameter and thickness of the ball of dough are inverselyproportional, when the ball of dough has a diameter less than thedesired recipe diameter, the ball of dough may cause a jam in theproduction line depending on how much the ball of dough was pressed.

The banded oven discharge 230 transfers the pressed dough balls 108 fromthe oven removal conveyor 228 to a cooling rack input conveyor 234. Forexample, the banded oven discharge 230 transfers all dough balls thathave a horizontal diameter greater than a minimum recipe value to thecooling rack input conveyor 234. Alternatively, all dough balls with adiameter greater than about 6 inches are transferred to the cooling rackinput conveyor 234.

The rejected product cart 232 is periodically emptied to prevent doughballs from overflowing out of the rejected product cart 232. Forexample, the rejected product cart 232 includes a plurality of sensorsthat determine the remaining capacity of the rejected product cart 232.When one or more of the sensors determine that the rejected product cart232 or a portion of the rejected product cart 232 is nearing or atmaximum capacity, the rejected product cart 232 is removed from thetransfer system 200 and another rejected product cart is placed belowthe banded oven discharge 230. For example, an operator of theproduction line receives an alert message indicating that the rejectedproduct cart 232 should be exchanged with another cart.

Alternatively, the transfer system 200 includes a conveyor, whichremoves incorrectly formed balls of dough from the transfer system 200.For example, the conveyor is located below the banded oven discharge 230and does not move until a sensor detects that a ball of dough is locatedon the conveyor. Upon detection, the conveyor activates and removes theball of dough away from the transfer system 200 and the banded ovendischarge 230.

The banded oven discharge 230 includes a drive roller 236 and a passiveroller 238, shown in FIG. 2B. The drive roller 236 moves a plurality ofsupport members 240 a-e (e.g., conveyors, transfer belts, or transferbands), which support the pressed dough balls 108 as the pressed doughballs 108 pass over the banded oven discharge 230 in a longitudinaldirection. The drive roller 236 is connected to a motor (not shown)which rotates the drive roller 236 in a clockwise direction, translatingthe support members 240 a-e longitudinally through the banded ovendischarge 230.

The passive roller 238 supports the ends of the support members 240 a-eopposite the drive roller 236. The passive roller 238 is centered on afirst horizontal plane different from a second horizontal plane at thecenter of the drive roller 236. For example, the first horizontal planeis above the second horizontal plane. Alternatively, the centers of thepassive roller 238 and the drive roller 236 lie on the same plane.

In some implementations, the passive roller 238 is powered by a motor.For example, both the passive roller 238 and the drive roller 236 areconnected to a motor (e.g., the same or different motors).Alternatively, the drive roller 236 is not connected to a motor and thepassive roller 238 is connected to a motor. Selection of which rollersare powered and/or connected to a motor can be determined by thelocation of the banded oven discharge 230 in the production line.

The diameters of the drive roller 236 and the passive roller 238 are thesame. For example, diameter of the rollers is between about 0.5 to about3 inches, preferably between about 0.75 to about 2 inches, morepreferably between about 1 to about 1.5 inches. Alternatively, thediameters of the drive roller 236 and the passive roller 238 aredifferent. For example, the drive roller 236 has a diameter of 0.75inches and the passive roller 238 has a diameter of 1.0 inch.

In certain implementations, the diameters of the drive roller 236 and/orthe passive roller 238 are associated with the width of the oven removalconveyor 228 and/or the width of the cooling rack input conveyor 234.For example, the diameter of the drive roller 236 is larger when thewidth of the oven removal conveyor 228 is about 60 inches wide comparedto when the width of the oven removal conveyor 228 is about 37 incheswide.

In various implementations, the diameters of the rollers are selectedbased on the material used to manufacture each of the rollers and toprevent the rollers from bending. For example, the diameter of the driveroller 236 is selected so that the driver roller 236 is strong enoughthat the driver roller 236 does not bend. In one example, when the driveroller 236 bends, the driver roller 236 may inadvertently deflect one ofthe pressed dough balls 108 off of the banded oven discharge 230.

In some implementations, when the diameter of the drive roller 236and/or the passive roller 238 is smaller, the rollers provide bettertransfer for the pressed dough balls 108. For example, a smallerdiameter for the drive roller 236 can reduce the possibility of apressed dough ball becoming stuck on the driver roller 236 or betweenthe drive roller 236 and one of the support members 240 a-e.

The drive roller 236 and the passive roller 238 are manufactured fromsteel based on the structural robustness of steel. In one example, therollers are manufactured from stainless steel based on the approvaland/or certification of stainless steel for food processing.

In some implementations, one or both of the rollers are manufacturedfrom aluminum in order to have a low mass and high wear resistance.Plastic can be used during the forming process of the drive roller 236and/or the passive roller 238 based on the low mass of plastic and theease of forming plastics in molds. Sometimes during the manufacturingprocess of one or both of the rollers wood is used. For example, one ormore parts of the rollers and made from wood. In variousimplementations, the drive roller 236 and/or the passive roller 238 aremade from a combination of materials.

In certain implementations, the drive roller 236 and/or the passiveroller 238 include materials and/or compounds not included in the otherroller. For example, the drive roller 236 is made from stainless steeland the passive roller 238 is made from steel and plastic.

The support members 240 a-e are manufactured from polyurethane. Forexample, the support members 240 a-e are belts which are made frompolyurethane. In some implementations, the support members 240 a-e aremanufactured from an elastomer that can be stretched and has a memory toretract to the original size and shape of the support members 240 a-e.For example, silicone is used to make the support members 240 a-e basedon the thermal stability, and low stick resistance of silicone. Invarious implementations, the support members 240 a-e are Eaglepolyurethane belting by Fenner Drives. In other implementations, thesupport members 240 a-e are manufactured by DuraBelt, Inc. In someexamples, the support members 240 a-e are manufactured from food gradeurethane.

In one example, the support members 240 a-e are made from Viton,manufactured by DuPont Performance Elastomers L.L.C., based on thetemperature range and good wear resistance of Viton. In someimplementations, the support members 240 a-e are manufactured frompolyvinyl chloride for the flexibility of polyvinyl chloride. In certainimplementations, Buna-N (or Nitrile) is used during manufacturing of thesupport members 240 a-e based on the low cost and wear resistance ofBuna-N.

The support members 240 a-e have a circular cross section. The circularcross section is optionally hollow in the center to reduce the amount ofmaterial used to manufacture the support members 240 a-e. In certainimplementations, the support members 240 a-e have a diamond crosssection to decrease the amount of surface area that contacts balls ofdough supported by the banded oven discharge. In some implementations,decreasing the amount of surface area that contacts the balls of doughreduces the likelihood that incorrectly formed products are transferredfrom the oven removal conveyor 228 to the cooling rack input conveyor234 without falling into the rejected product cart 232.

In other implementations, the support members 240 a-e have a “V” orinverted “V” cross section. The inverted “V” cross section can beselected to provide sufficient support to the pressed dough balls 108wile reducing the amount of surface area of the support members 240 a-ethat contacts the pressed dough balls 108. In some implementations, thepoint of the inverted “V” is removed to increase the amount of surfacearea that contacts the pressed dough balls 108 while keeping the amountof surface area small.

In various implementations, the support members 240 a-e have an ovalcross section with the longer diameter in a vertical direction. Havingan oval cross section decreases the amount of surface area contactingthe balls of dough supported by the banded oven discharge whiledecreasing the amount the support members 240 a-e sag when supporting aball of dough. The support members 240 a-e can have a half-oval orhalf-circular cross section. The base of the support members 240 a-e(e.g., the flat surface) is firmly supported by the drive roller 236while the half circle surface contacts the pressed dough balls 108.

In some implementations, the support members 240 a-e are textured inorder to improve contact between the support members 240 a-e and ballsof dough supported on the support members 240 a-e. For example, usingtextured support members 240 a-e can increase the speed of the presseddough balls 108 as the pressed dough balls 108 move across the bandedoven discharge 230 because the texturing helps prevent the pressed doughballs 108 from slipping.

The hardness of the support members 240 a-e is between about 50 to about100 Durometer, preferably between about 70 to about 90 Durometer, morepreferably about 83 Durometer, for A or D type testing according to ASTMD2240 testing for softer or harder plastics. The hardness can beselected based on the diameter of the pressed dough balls 108. Thehardness of the support members 240 a-e can be selected to reduce theamount of wear on the support members 240 a-e during processing.

The diameter of each of the support members 240 a-e is between about0.125 to about 0.5 inches, preferably between about 0.1875 to about0.375 inches, more preferably between about 0.25 to about 0.3125 inches.For example, the diameter of the support members 240 a-e is selectedbased on the diameter of the pressed dough balls 108 and/or the diameterof the balls of dough 104. In this example, the diameters of the supportmembers 240 a-e are selected in order to support the pressed dough balls108 as the pressed dough balls 108 are transferred across the bandedoven discharge 230. The diameter of the support members 240 a-e isselected to reduce the possibility of one of the pressed dough balls 108becoming stuck on one of the support members 240 a-e or between one ofthe support members 240 a-e and the drive roller 236.

In certain implementations, the diameter of the support members 240 a-eis selected so that a minimum amount of power is required to drive thesupport members 240 a-e. For example, when the support members 240 a-ehave a small diameter, less power is required to drive the supportmembers 240 a-e than if the support members 240 a-e have a largerdiameter and a larger mass.

In some implementations, the diameter of the support members 240 a-e isselected so that the support members 240 a-e easily conform to the driveroller 236 and/or the passive roller 238. In various implementations,the diameter of the support members 240 a-e is selected to reduce thefrequency and/or possibility of one of the support members 240 a-ebreaking.

In certain implementations, the drive roller 236 and/or the passiveroller 238 include a plurality of grooves 242 a-b corresponding with thesupport members 240 a-e. For example, the drive roller 236 and thepassive roller 238 include the grooves 242 a-b to support the supportmembers 240 a-e and prevent the support members 240 a-e from sliding inthe latitudinal direction (i.e., to one of the sides of the banded ovendischarge 230).

In these implementations, when the pressed dough balls 108 move acrossthe banded oven discharge 230, the drive roller 236 and the passiveroller 238 support the pressed dough balls 108. For example, the topsurface the drive roller 236 is flush with the top surfaces of thesupport members 240 a-e.

In one example, as a dough ball moves onto the banded oven discharge130, the drive roller 236 supports the leading edge of the dough ball,and as the leading edge moves across the banded oven discharge 130, thepassive roller 238 begins to support the leading edge. When anon-pressed or incorrectly formed ball of dough moves onto the bandedoven discharge 130, for example, the leading edge of the incorrectlyformed ball of dough contacts the drive roller 236 before theincorrectly formed ball of dough falls through the banded oven discharge230 and into the rejected product cart 232 (e.g., the incorrectly formedball of dough does not contact the passive roller 238).

In certain implementations, the shape of the grooves 242 a-b correspondswith the shape of the support members 240 a-e. For example, when thesupport members 240 a-e have a circular cross section, the grooves 242a-b have an inverted “U” shape. In another example, when the supportmembers 240 a-e have an inverted “V” shape or a pentagonal shape, thegrooves 242 a-b are rectangular.

The width of the grooves 242 a-b corresponds to the width of the supportmembers 240 a-e. For example, the width of the grooves 242 a-b isslightly larger than the width of the support members 240 a-e. Thegrooves 242 a-b are between about 0.125 to about 0.5 inches wide,preferably between about 0.25 to about 0.32 inches wide, preferablyabout 0.278 inches wide.

Similarly, the height of the grooves 242 a-b corresponds to the heightof the support members 240 a-e. For example, the height of the grooves242 a-b is between about 0.125 to about 0.5 inches, preferably betweenabout 0.125 to about 0.375 inches, more preferably between about 0.125to about 0.3125 inches. In some implementations, the height of thegrooves 242 a-b is less than the height of the support members 240 a-e.For example, each of the grooves 242 a-b has a height of 0.125 inchesand each of the support members 240 a-e has a height of 0.25 inches.

The gap L between the drive roller 236 and the passive roller 238, shownin FIG. 2C, has a minimum length of about 1.5 inches. The maximum lengthof the gap L between the drive roller 236 and the passive roller 238 isabout 2 inches less than the diameter of the pressed dough balls 108.For example, the length of the gap is selected to be greater than thediameter of incorrectly formed balls of dough that may cause a jam inthe production line and 2.0 inches less than the desired recipe diameterof the pressed dough balls 108.

In one example, when the diameter of the pressed dough balls 108 isabout 10 inches, the length of the gap L is between about 5 to about 8.5inches, preferably between about 6.5 to about 8 inches. In anotherexample, when the diameter of the pressed dough balls 108 is about 6.0inches, the length of the gap L is between about 1.5 to about 4 inches,preferably between about 2.5 to about 3.75 inches, more preferablybetween about 3 to about 3.5 inches.

The length of the support members 240 a-e is determined based on the gapL between the drive roller 236 and the passive roller 238. For example,when the gap L has a longer length, the support members 240 a-e have alonger length than compared to a smaller gap L corresponding withsupport members 240 a-e with a shorter length.

The width W between two adjacent support members 240 a-e (e.g., thesupport member 240 a and the support member 240 b), as shown in FIG. 2D,is selected so that balls of dough with a thickness greater than apredetermined thickness, which may cause a jam in the production line,are rejected by the banded oven discharge 230 and removed from theproduction line. For example, since the diameter of a ball of dough isinversely proportional to the thickness of the ball of dough, a processrecipe includes a minimum value for the width W so that balls of doughwith a thickness greater than the predetermined thickness are removedfrom the production line based on the diameter of the ball of dough.

The width W is between about 1 to about 6 inches, preferably betweenabout 1.5 to about 5 inches, more preferably between about 2 to about 5inches. The width W is selected so that the width W is about the same asor greater than the diameter of the incorrectly formed balls of doughand less than the diameter of the pressed dough balls 108.

For example, if a 3 inch diameter non-pressed ball of dough forms a10.00 inch diameter pressed dough ball, the width W between adjacentsupport members 240 a-e is between about 4 to about 6 inches, preferablybetween 4 to about 5 inches. In this example, an incorrectly formed ballof dough (e.g., with a diameter around 4 inches) will be rejected by thebanded oven discharge 230 and fall between the support members 240 a-e(e.g., with a width W of around 4 inches) while the pressed dough ball244 is transferred across the banded oven discharge 230.

In some implementations, the width W between each pair of adjacentsupport members 240 a-e is approximately the same. In otherimplementations, the width W between each pair of adjacent supportmembers 240 a-e is different. For example, the distance between adjacentsupport members is selected based on the recipe used by the productionline.

The center of the balls of dough that the oven removal conveyor 228transfers onto the banded oven discharge 230 (e.g., a pressed dough ball244 and/or an incorrectly formed ball of dough 246) approximately alignswith one of three longitudinal axes B1-3 identified based on the presscycle layout.

When the press cycle layout used by the production line includes threelongitudinal columns of balls of dough, the transfer system 200 includesthe three longitudinal axes B1-3 corresponding with the threelongitudinal axes A1-3 of the dough pressing apparatus 100 a. If therecipe used by the product line changes and includes a change in thenumber of longitudinal columns of balls of dough, the number of axes inthe transfer system 200 and the dough pressing apparatus 100 a isadjusted to reflect the change.

In one example, when the recipe is changed from a 3×3 press cycle to a5×5 press cycle, both the dough pressing apparatus 100 a and thetransfer system 200 include five longitudinal axes corresponding to alongitudinal column of the press cycle. When a ball of dough moves alonga first axis in the dough pressing apparatus 100 a (e.g., the axis A1)the ball of dough later moves along a corresponding first axis in thetransfer system 200 (e.g., the axis B1) once the ball of dough isremoved from the oven 100 b and placed in the transfer system 200.

In this example, the location of the support members 240 a-e is changedfrom the original configuration for the 3×3 press cycle. For example,the support members 240 a-e are manually moved to correspond with thefive axes associated with the new recipe so that each axis is centeredbetween two adjacent support members. Alternatively, the support members240 a-e are automatically moved to new locations by the production lineand/or a robot. For example, the drive roller 236 and the passive roller238 do not have grooves and a robot arm automatically moves the supportmembers 240 a-e to new positions.

The three longitudinal axes B1-3 approximately align with the centers ofa pair of adjacent support members. In one example, the longitudinalaxis B2 is approximately centered between the support members 240 a-band the longitudinal axis B1 is approximately centered between thesupport members 240 c-d.

Centering the longitudinal axes B1-3 between a pair of adjacent supportmembers allows each of the pressed dough balls 108 to be supported by atleast two of the support members 240 a-e while incorrectly formed ballsof dough are not supported by any of the support members 240 a-e. In oneexample, the pressed dough ball 244 is supported by the support members240 a-b while the incorrectly formed ball of dough 246 falls through anaperture 248 between the drive roller 236 and the passive roller 238 andinto the rejected product cart 232 (e.g., the incorrectly formed ball ofdough 246 is not supported by either of the support members 240 c-d).

In certain implementations, the pressed dough ball 244 is supported byat least two of the support members 240 a-e to prevent the edges of thepressed dough ball 244 from becoming pinched between one of the supportmembers 240 a-e and the drive roller 236 or the passive roller 238. Forexample, if the pressed dough ball 244 is supported by a single supportmember, the pressed dough ball 244 may jam between the single supportmember and the passive roller 238.

In some implementations, an incorrectly formed ball of dough issupported by one of the support members 240 a-e when moving onto thebanded oven discharge 230. For example, the incorrectly formed ball ofdough 246 is supported by the support member 240 c. In this example, theincorrectly formed ball of dough 246 will fall off the support member240 c and into the rejected product cart 232 because the surface area ofthe support member 240 c is sufficient to support the pressed dough ball244 in conjunction with one or more additional support members but isinsufficient to support the incorrectly formed ball of dough 246 alone.

In some implementations, some or all of the transfer system 200 isreplaced or exchanged when a new recipe is selected for the productionline. For example, the oven removal conveyor 228 and the banded ovendischarge 230 are removed from the transfer system 200 and another ovenremoval conveyor and banded oven discharge are placed in the transfersystem (e.g., where the replacement banded oven discharge is configuredfor the five axes corresponding to the new recipe).

In some implementations, the drive roller 236 and/or the passive roller238 include a plurality of the grooves 242 a-b such that there is not aone to one correlation between the support members 240 a-e and thegrooves 242 a-b. For example, the drive roller 236 includes two grooves256 a-b adjacent to the groove 242 a, with one groove on either side ofthe groove 242 a. While the production line is processing a recipe, thesupport member 240 c can be moved to either of the adjacent grooves 256a-b to improve processing of the pressed dough balls 108.

Continuing the example, when the edge of a pressed dough ball is closeto the edge of the support member 240 c, the pressed dough ball maybecome stuck between the support member 240 c and the drive roller 236.To reduce the possibility of a jam, the support member 240 c can bemoved to the groove adjacent the groove 242 a where positioning of thesupport member 240 c in the adjacent groove reduces the distance betweenthe adjacent support members that the pressed dough ball is supportedby.

In another example, the drive roller 236 includes a plurality of groovesalong the entire length of the drive roller 236. For example, each ofthe grooves is adjacent to two other grooves with the exception of thetwo grooves on either end of the drive roller 236. Including groovesalong the entire length of the drive roller 236 and/or the passiveroller 238 allows the support members 240 a-e to be moved to differentpositions along the rollers depending on the process recipe used by theproduction line.

For example, the location of the support members 240 a-e can be adjustedduring processing to reduce the chance that one of the pressed doughballs 108 will be caught in the banded oven discharge 230. Additionally,when the recipe used by the production line is changed, the position ofthe support members 240 a-e can be altered without replacing the bandedoven discharge 230 with a banded oven discharge with anotherconfiguration.

When the banded oven discharge 230 includes a plurality of the grooves242 a-b such that there is not a one to one correspondence between thegrooves 242 a-b and the support members 240 a-e, the support members 240a-e can be manually moved between adjacent grooves depending on thedesired recipe parameters or operating conditions. Alternatively, thebanded oven discharge 230 includes an automated system (e.g., a robot)that moves the support members 240 a-e between adjacent grooves. In thisimplementation, the banded oven discharge 230 includes a holding area(not shown) where support members are positioned when not in use (e.g.,at one or both ends of the driver roller 236 and the passive roller238).

The distance between adjacent grooves is selected so that the supportmembers 240 a-e do not move between the adjacent grooves withoutinteraction with the transfer system 200 and so that the support members240 a-e can be easily moved when required for a recipe or by anoperator. For example, one of the support members 240 a-e moves to anadjacent groove when an operator physically moves the support member anddoes not move between grooves otherwise. In another example, a supportmember moves between adjacent grooves when a robot or automated systemmoves the support member to the adjacent groove.

In one example, the distance between adjacent grooves is proportional tothe width of the support members 240 a-e. In certain implementations,the distance between adjacent grooves is zero. For example, when onegroove ends, another groove begins at the ending point. In this example,the edges of the grooves are rounded to reduce the possibility of damageto the support members 240 a-e when a support member is moved betweenadjacent grooves.

In some implementations, the distance between adjacent grooves isselected to minimize the possibility of a support member moving betweenadjacent grooves without system interaction. For example, the distancebetween adjacent grooves is selected so that it is unlikely for asupport member to move between grooves without interaction with anoperator or another part of the transfer system 200.

In various implementations, the banded oven discharge 230 is locatedbetween the cooling rack input conveyor 234 and a cooler (e.g., thecooler 100 d). The location of the banded oven discharge 230 is selectedbased on the layout of the production line and the types of toolsincluded in the production line.

In certain implementations, an oven removal system 250, shown in FIG.2E, includes a plurality of rollers 252 a-f, which drive the ovenremoval conveyor 228. The rollers 252 a-f move the oven removal conveyor228 in a longitudinal direction along the longitudinal axes B1-3.

Each of the rollers 252 a-f is positioned along one of the longitudinalaxes B1-3 to support balls of dough that move along the path defined bythe longitudinal axes B1-3. For example, as the pressed dough ball 244moves along the longitudinal axis B2, the roller 252 b and the roller252 e support the pressed dough ball 244. Similarly, as the incorrectlyformed ball of dough 246 moves along the longitudinal axis B1, theroller 252 c and the roller 252 f support the incorrectly formed ball ofdough 246.

Alternatively, some of the rollers 252 a-f are located in the ovenremoval system 250 along a longitudinal axes that does not correspondwith a path traveled by one of the pressed dough balls 108. For example,when the production line is initially configured for three longitudinalaxes and later reconfigured for a recipe with five longitudinal axes,some of the rollers 252 a-f may not lie on an axis defined by one of thefive longitudinal axes associated with the new recipe.

In some implementations, each of the rollers 252 a-f comprises doublerollers to support the oven removal conveyor 228.

The rollers 252 a-f are connected to a motor 254. The motor 254 rotatesthe rollers 252 a-f while the production line processes the presseddough balls 108 (e.g., the pressed dough ball 244). As the rollers 252a-f rotate, the rollers 252 a-f drive the oven removal conveyor 228,which transfers the pressed dough ball 244 to the banded oven discharge230.

FIG. 3 illustrates an example of a system 300 for selecting a productionline recipe. The system 300 includes a recipe selection system 302,which receives user input and identifies parameters associated with aselected recipe.

For example, the recipe selection system 302 includes a user inputmodule 304 that receives input from a user. The input can be selectionof a recipe from a recipe database 306. Alternatively, a user candirectly input a recipe into the recipe selection system 302 into a userinterface associated with user specified recipes.

A monitor 308, included in the recipe selection system 302, presentsinformation to a user. For example, the monitor 308 displays a userinterface that allows a user to enter recipe information into the recipeselection system 302 or select a recipe from the recipe database 306.

The monitor 308 can display confirmation information that verifies arecipe selection or recipe information entered by the user. For example,the user input module 304 receives user input identifying a recipe, therecipe selection system 302 validates the recipe to ensure that therecipe parameters are acceptable, and the monitor 308 presents a recipeconfirmation to the user.

A loading station module 310, included in the recipe selection system302, identifies the recipe parameters associated with a loading station312 included in a production line 314. For example, the loading stationmodule 310 determines the pattern of dough balls used by the recipe.

In some implementations, the loading station module 310 determines ifthe loading station positioned in the production line is configured forthe recipe. For example, the loading station module 310 determines thata 3×3 pattern of dough balls is required by the selected recipe and thatthe production line is currently setup for a 4×3 pattern of dough balls.The loading station module 310 can provide a message (e.g., on themonitor 308) to an operator of the production line indicating that theloading station 312 should be configured for a 3×3 pattern of doughballs.

Alternatively, the loading station module 310 provides the productionline 314 with information indicating that the loading station 312 shouldbe reconfigured. For example, the production line 314 receives theinformation from the loading station module 310 and identifies a 3×3dough ball loader to place on the loading station 312. The productionline automatically removes the 4×3 dough ball loader from the loadingstation 312 and attaches the 3×3 dough ball loader onto the loadingstation 312 without user or operator interaction.

A pressing station module 316, included in the recipe selection system302, configures a pressing station 318 (e.g., the pressing station 106)in the production line 314. For example, the pressing station module 316identifies the pattern of dough balls specified by the selected recipeand determines the configuration for the pressing station 318.

In certain implementations, the production line 314 receives informationfrom the pressing station module 316 that identifies the configurationfor the pressing station 318. For example, the configuration includesadjustments and/or changes the production line 314 automatically makesto the pressing station 318 for the selected recipe.

In one example, the production line 314 replaces a skin attached to apressing platen in the pressing station 318. In another example, theproduction line 314 (or a controller in the production line 314) adjuststhe pressure used at the pressing station 318 when forming pressed doughballs. In this example, the pressure of the pressing station 318 isadjusted for the press cycle associated with the selected recipe toincrease the uniformity of the pressed dough balls.

A banded discharge module 320, included in the recipe selection system302, identifies one or more adjustments for a banded discharge 322 basedon the selected recipe. For example, the banded discharge module 320determines that a recipe parameter identifies five longitudinal axes andthe banded discharge 322 is configured for three longitudinal axes. Inthis example, the banded discharge module 320 notifies an operator ofthe required change. The notification can include identification of thedistance between adjacent transfer belts and/or the recommended locationof the transfer belts in the banded discharge 322.

In some implementations, the production line 314 automatically adjuststhe banded discharge 322 based on parameter adjustments identified bythe banded discharge module 320. For example, the production line 314automatically moves one or more support members to align with the fivelongitudinal axes specified by the selected recipe. In one example, theproduction line 314 places two support members equidistant from each ofthe five longitudinal axes. In this example, the support members areplaced about 3 inches or less from the associated longitudinal axis.

In certain implementations, when the recipe used by the production line314 changes, the banded discharge module 320 determines that the bandeddischarge 322 does not need any configuration changes. For example, whenthe banded discharge 322 is configured for a 3×3 press cycle (with threelongitudinal columns of dough balls) and a selected recipe requires a3×4 press cycle (with three longitudinal columns and four latitudinalrows of dough balls), the locations of the support members in the bandeddischarge 322 do not need to be adjusted.

In various implementations, the banded discharge module 320 receivesnotifications from the banded discharge 322. For example, when arejected product cart is full and needs be removed from the productionline 314 the production line 314 provides the banded discharge module320 with a cart removal notification. Upon receiving the cart removalnotification, the banded discharge module 320 presents a message on themonitor 308 to an operator indicating that the rejected product cartshould be exchanged.

The recipe selection system 302 communicates with the production line314 through a network 324. For example, the network 324 is a local areanetwork at a production facility that allows a remote user to monitorthe production facility. In another example, the network 324 connectsseparate stations in the production line 314 with the recipe selectionsystem 302 and does not allow remote access to the production line 314or the recipe selection system 302.

FIG. 4 is a schematic diagram of a generic computer system 400. Thesystem 400 is optionally used for the operations described inassociation with any of the computer-implemented methods describedpreviously, according to one implementation. The system 400 includes aprocessor 410, a memory 420, a storage device 430, and an input/outputdevice 440. Each of the components 410, 420, 430, and 440 areinterconnected using a system bus 450. The processor 410 is capable ofprocessing instructions for execution within the system 400. In oneimplementation, the processor 410 is a single-threaded processor. Inanother implementation, the processor 410 is a multi-threaded processor.The processor 410 is capable of processing instructions stored in thememory 420 or on the storage device 430 to display graphical informationfor a user interface on the input/output device 440.

The memory 420 stores information within the system 400. In oneimplementation, the memory 420 is a computer-readable medium. In oneimplementation, the memory 420 is a volatile memory unit. In anotherimplementation, the memory 420 is a non-volatile memory unit.

The storage device 430 is capable of providing mass storage for thesystem 400. In one implementation, the storage device 430 is acomputer-readable medium. In various different implementations, thestorage device 430 is optionally a floppy disk device, a hard diskdevice, an optical disk device, or a tape device.

The input/output device 440 provides input/output operations for thesystem 400. In one implementation, the input/output device 440 includesa keyboard and/or pointing device. In another implementation, theinput/output device 440 includes a display unit for displaying graphicaluser interfaces.

In some examples, the features described are implemented in digitalelectronic circuitry, or in computer hardware, firmware, software, or incombinations of them. The apparatus is optionally implemented in acomputer program product tangibly embodied in an information carrier,e.g., in a machine-readable storage device or in a propagated signal,for execution by a programmable processor; and method steps areperformed by a programmable processor executing a program ofinstructions to perform functions of the described implementations byoperating on input data and generating output. The described featuresare optionally implemented advantageously in one or more computerprograms that are executable on a programmable system including at leastone programmable processor coupled to receive data and instructionsfrom, and to transmit data and instructions to, a data storage system,at least one input device, and at least one output device. A computerprogram is a set of instructions that are optionally used, directly orindirectly, in a computer to perform a certain activity or bring about acertain result. A computer program is optionally written in any form ofprogramming language, including compiled or interpreted languages, andit is deployed in any form, including as a stand-alone program or as amodule, component, subroutine, or other unit suitable for use in acomputing environment.

Suitable processors for the execution of a program of instructionsinclude, by way of example, both general and special purposemicroprocessors, and the sole processor or one of multiple processors ofany kind of computer. Generally, a processor will receive instructionsand data from a read-only memory or a random access memory or both. Theessential elements of a computer are a processor for executinginstructions and one or more memories for storing instructions and data.Generally, a computer will also include, or be operatively coupled tocommunicate with, one or more mass storage devices for storing datafiles; such devices include magnetic disks, such as internal hard disksand removable disks; magneto-optical disks; and optical disks. Storagedevices suitable for tangibly embodying computer program instructionsand data include all forms of non-volatile memory, including by way ofexample semiconductor memory devices, such as EPROM, EEPROM, and flashmemory devices; magnetic disks such as internal hard disks and removabledisks; magneto-optical disks; and CD-ROM and DVD-ROM disks. Theprocessor and the memory are optionally supplemented by, or incorporatedin, ASICs (application-specific integrated circuits).

To provide for interaction with a user, the features in some instancesare implemented on a computer having a display device such as a CRT(cathode ray tube) or LCD (liquid crystal display) monitor fordisplaying information to the user and a keyboard and a pointing devicesuch as a mouse or a trackball by which the user provides input to thecomputer.

The features are optionally implemented in a computer system thatincludes a back-end component, such as a data server, or that includes amiddleware component, such as an application server or an Internetserver, or that includes a front-end component, such as a clientcomputer having a graphical user interface or an Internet browser, orany combination of them. The components of the system are connected byany form or medium of digital data communication such as a communicationnetwork. Examples of communication networks include, e.g., a LAN, a WAN,and the computers and networks forming the Internet.

The computer system optionally includes clients and servers. A clientand server are generally remote from each other and typically interactthrough a network, such as the described one. The relationship of clientand server arises by virtue of computer programs running on therespective computers and having a client-server relationship to eachother.

A number of embodiments have been described. Nevertheless, it will beunderstood that various modifications are optionally made withoutdeparting from the spirit and scope of this disclosure. Accordingly,other embodiments are within the scope of the following claims.

1. A system comprising: a first conveyor to transfer a plurality ofcomestibles along a production line, the first conveyor comprising atleast two support members, each pair of adjacent support members being apredetermined distance apart, wherein the plurality of comestiblesincludes a first subset of comestibles and a second subset ofcomestibles, wherein each of the first subset of comestibles has a firstdiameter substantially greater than the predetermined distance betweenadjacent support members to allow the first conveyor to transport thefirst subset of comestibles to a second conveyor in the production line;and wherein the second subset of comestibles is separate from the firstsubset of comestibles, each of the second subset of comestibles having asecond diameter about the same as or less than the predetermineddistance between adjacent support members, and each of the second subsetof comestibles are not transported to the second conveyor and are to beremoved from the production line.
 2. The system of claim 1, wherein eachof the at least two support members are parallel.
 3. The system of claim1, wherein the predetermined distance between adjacent support membersis adjustable.
 4. The system of claim 3, where the predetermineddistance between adjacent support members is adjusted based on a recipeselected for the production line, wherein the recipe includes a desireddiameter for the plurality of comestibles and the predetermined distancebetween adjacent support members is less than the desired diameter. 5.The system of claim 4, wherein the first conveyor further comprises afirst roller and a second roller spaced apart from the first roller,wherein the first roller and the second roller support the at least twosupport members.
 6. The system of claim 5, wherein a longitudinaldistance between the first roller and the second roller is based on therecipe selected for the production line and the longitudinal distance isless than the desired diameter for the plurality of comestibles.
 7. Thesystem of claim 4, wherein each of the first subset of comestibles andthe second subset of comestibles has a thickness inversely proportionalto the diameter of the comestible, wherein the thickness of each of thecomestibles is determined by an amount the comestible was pressed,wherein the predetermined distance between adjacent support members isselected to reject comestibles with a thickness greater than apredetermined thickness.
 8. The system of claim 1, wherein each of thesecond subset of comestibles fall between a pair of adjacent supportmembers and are removed from the production line.
 9. The system of claim8, further comprising a third conveyor to transfer one of the secondsubset of comestibles away from the first conveyor after the one of thesecond subset of comestibles falls between adjacent support members inthe first conveyor.
 10. The system of claim 1, wherein each of the atleast two support members is a belt.
 11. The system of claim 10, whereineach of the at least two support members is manufactured frompolyurethane.
 12. The system of claim 10, wherein each of the at leasttwo support members is manufactured from an elastomer.
 13. The system ofclaim 10, wherein the hardness of each of the at least two supportmembers is between about 50 to about 100 Durometer.
 14. The system ofclaim 10, wherein each of the at least two support members has aninverted “V” cross section.
 15. The system of claim 10, wherein each ofthe at least two support members has a diamond cross section.
 16. Amethod comprising: receiving, at a first conveyor in a production line,a plurality of comestibles comprising a first subset of comestibles anda second subset of comestibles separate from the first subset ofcomestibles, the first conveyor comprising at least two support members,each pair of adjacent support members being a predetermined distanceapart; transferring, by a pair of adjacent support members of the atleast two support members, a first comestible from the first conveyor toa second conveyor separate from the first conveyor, the second conveyorincluded in the production line, the first subset of comestiblesincluding the first comestible, each of the first subset of comestibleshaving a first diameter substantially greater than the predetermineddistance between adjacent support members; and rejecting, by the pair ofadjacent support members, a second comestible, the second subset ofcomestibles including the second comestible, each of the second subsetof comestibles having a second diameter about the same as or less thanthe predetermined distance between adjacent support members.
 17. Themethod of claim 16, further comprising adjusting the predetermineddistance between adjacent support members.
 18. The method of claim 17,wherein the predetermined distance between adjacent support members isadjusted based on a recipe selected for the production line, the recipeincluding a desired diameter for the plurality of comestibles, and thepredetermined distance between adjacent support members being about 6inches or less.
 19. The method of claim 18, wherein the first conveyorfurther comprises a first roller and a second roller spaced apart fromthe first roller, wherein the transferring comprises translating, by thefirst roller, the at least two support members.
 20. The method of claim19, wherein a longitudinal distance between the first roller and thesecond roller is based on the recipe selected for the production lineand the longitudinal distance is less than the desired diameter for theplurality of comestibles.
 21. The method of claim 16, wherein therejecting comprises removing the second comestible from the productionline.
 22. The method of claim 21, further comprising pressing, at apressing station, a first dough ball to form the first comestible withthe first diameter.
 23. The method of claim 22, further comprisingcooling, by a cooler, the first comestible after the transferring. 24.The method of claim 23, further comprising baking, by an oven, the firstcomestible before the transferring.
 25. The method of claim 23, furthercomprising moving, by a third conveyor, the second comestible away fromthe first conveyor after the rejecting.